Brush fabricating apparatus

ABSTRACT

The present invention is directed to an apparatus for making brushes of the type in which a metallic ferrule, previously filled with bristles formed of thermoplastic material, is subjected to a heating step which fuses the exposed ends of the bristles internally of the ferrule into an integrated mass, the heating step at the same time preferably resulting in the formation of a connection between the molten material and the ferrule. The apparatus includes a conveyor progressively moving from a loading zone to a heating zone and is characterized by the provision of magnetic means for supporting the ferrules, and cam means interposed between the loading and heating zones which engage the supported ferrules and accurately position the same a predetermined selected distance from the heating units, thus automatically to assure that the bristles are exposed to a precisely measured quantity of heat.

United States Patent 1191 Weiss 1111 3,834,863 14 Sept. 10, 1974 [54] BRUSH FABRICATING APPARATUS Primary ExaminerJohn J. Camby [75] Inventor. GerhartWe1ss,Flush1ng, N.Y. Assistant Examiner Hemy C. Yuen Assigneei Baker Brush New York, Attorney, Agent, or Firm-Mark T. Basseches; Paula N.Y. T. Basseches 22 F] d: 4, 1974 1 16 Jan 57 ABSTRACT [211 App! 430788 The present invention is directed to an apparatus for Related US. Application Data making brushes of the type in which a metallic ferrule, [63] continuatiomimpart f Sen 309,347, 24, previously filled with bristles formed of thermoplastic 1972. material, is subjected to a heating step which fuses the exposed ends of the bristles internally of the ferrule [52] US. Cl 432/121, 219/388, 300/2, into a in g mass, the i g t p at e sa e 432/266 time preferably resulting in the formation of a connec- [51] Int. Cl A4611 3/08 tion b tween the molten material and the ferrule.

8, a 432/121, 120, 153, 239, 243, 86; 219/388, moving from a loading zone to a heating zone and is 411; 198/41; 15/ 1 132 characterized by the provision of magnetic means for supporting the ferrules, and cam means interposed References Cited between the loading and heating zones which engage UNITED STATES PATENTS the supported ferrules and accurately position the 2,303,800 12/1942 Swann 300/2 Same a predetermined Selected distance from the 2,643,157 6/1953 Handman et al. 300 21 heating units, thus automatically to assure that the 2,743,003 4/ 1956 Allen 432/239 bristles are exposed to a precisely measured quantity 3,017,307 l/1962 Halliburton 300/21 of heat, 3,154,346 10/1964 Anderson 300/2 3,785,475 1/1974 Maynard 198/41 4 Claims, 10 Drawmg Flgul'es iii H I ':I

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l 1,, e11, 11, 111 33 1 Q n F=- i t T 1 9 I 1 F151 6 67 t it 65 PAIENIED SEP 1 01914 I UEJ I SMU 1 UF 4 PAIENTEDSEP 01w 3983 1.883

SHEEI 3 0F 4 BRUSH FABRICATING APPARATUS This application is a continuation-in-part of application Ser. No. 309,347, filed Nov. 24, 1972, entitled IM- PROVED BRUSH CONSTRUCTION AND METHOD OF MAKING THE SAME.

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is in the field of brush forming apparatus, and particularly in the field of apparatus for fabricating brush components through the application of heat to a ferrule which has been stuffed with bristles.

2. The Prior Art As more fully set forth in the above referred to copending application, brushes have typically been fabricated by providing a ferrule and inserting within the ferrule a multiplicity of bristles, such that the free ends of the bristles which will be used for painting, project outwardlyof the ferrule. The opposite ends of the bristles, which are preferably more or less aligned at a preselected level within the ferrule, are subjected to a heating step which causes the uppermost increments of the bristles to melt, fusing the bristles together within the ferrule into an integral mass. Preferably, as set forth in the aforesaid copending application, the inner circumference of the ferrule has been treated with a heat activated adhesive composition reactive with the fused components of the bristles, whereby a firm and pennanent bond between the bristles inter se and the bristles and ferrule is effected.

A preferred bristle material for use in the above described method is a nylon material which consists of long chain polyamide material.

It will be readily recognized that the bond between the bristles and the bond between the molten bristle material and the ferrule are largely dependent upon the quantum of heat which is applied in the formation of the ferrule-bristle subassembly.

It has been determined to be imperative for the production of a satisfactory brush that the amount of heat applied be maintained more or less precisely within selected limits. Manifestly, if the bristle ends do not receive sufficient heat, the bond between the bristles, and between the bristles and the ferrule will not be sufficiently strong, with the result that individual bristles may separate from the mass, or the mass may be removed from the ferrule. If, on the other hand, the bristle ends are subjected to too much heat, there is danger of over-melting, carbonization of the bristle ends, and- /or the adhesive with which the ferrule is treated.

It will be readily recognized that the heating effects of a heat source on the bristle ends are, in large measure, dependent upon the distance of the ends from the source, such heating effects varying in proportion to the square of the distance between the ends and the source.

SUMMARY The present invention is directed to apparatus for forming brushes or brush components through the utilization of a heating step wherein the quantum of energy to which the bristle ends within the ferrule are subjected may be accurately controlled, and involves particularly means for automatically accurately adjusting the spacing between the ferrule and the heat source. The apparatus includes a conveyor having increments progressively advanced from a loading zone to a heating zone, the increments including permanentmagnet means and guide means for coaction with the side edges of the ferrules.

The ferrules may be loaded in a more or less haphazard fashion simply by securing the ferrules to the mag net means in such manner that the uppermost edge of the ferrule projects a distance above or is exposed beyond the upper terminus of the guide means. Cam means are provided at an intermediate stage between the loading and heating zones, which cam means are interposed in the path of the uppermost edge of the ferrules carried on the magnets.

As the conveyor advances the ferrule toward the heating zone, the cam means engage the lead edges of the ferrules and slidingly shift the ferrules while the same are supported on the magnets, so as to orient the ferrules at a predetermined position relative to the magnets, the guide means, by reason of their guiding influence on the sides of the ferrules, precluding any tendency toward tilting movement of the ferrules. In this manner, the precise spacing between the ferrules and the heat source may be achieved, notwithstanding a haphazard loading of the ferrules in the loading zone.

Accordingly, it is an object of the present invention to provide an apparatus for manufacturing brushes and/or brush components through a heating step, which apparatus is characterized by means for precisely and automatically orienting the ferrules in a selected spaced relation to the heat source.

A further object of the invention is the provision of a device of the type described which includes guide means for preventing any tilting movement of the ferrules in the course of adjusting the spacing, as aforesaid.

Still a further object of the invention is the provision of apparatus of the type described wherein ferrous ferrules are supported on permanent magnets fixed to the conveyor, the apparatus including a cam in the path of the edge of the ferrule most closely approaching the heat source, whereby the cam and ferrule will interact, sliding the ferrules while the same are supported on the permanent magnets to a selected desired position relative to the magnets.

Still a further object of the invention is the provision of a device of the type described and including guide means disposed adjacent the side edges of the ferrules whereby movement of the ferrules relative to the magnets is confined to a selected desired direction, and tilting of the ferrules is prevented.

Still a further object of the invention is the provision of a device of the type described wherein the formed brush sub-components are automatically ejected at the conclusion of the heating cycles To attain these objects and such further objects as may appear herein or be hereinafter pointed out, reference is made to the accompanying drawings, forming a part hereof, in which:

FIG. 1 is a top plan view of a brush forming apparatus of the type described;

FIG. 2 is a side elevational view of the apparatus of FIG. 3;

FIG. 3 is an end elevational view of the apparatus of FIG. 1;

FIG. 4 is a fragmentary perspective view of the ferrule aligning station;

FIG. v5 is a magnified fragmentary side elevational view of the said aligning station;

FIG. 6 is a perspective view of a portion of the heating zone, depicting a single brush sub-componnt in the course of the heating step;

FIG. 7 is a vertical section taken on the line 77 of FIG. 6;

FIG. 8 is a top view of an increment of the conveyor and associated brush support mechanism for holding the bristle components;

FIG. 9 is a side view of the portions illustrated in FIG.

FIG. 10 is a vertical section taken on the line 1010 of FIG. 9.-

As conducive to an understanding of the present invention, there is shown in FIGS. 1 to 3 a brush fabricating apparatus including a support frame 10 having a platform 11 on which is mounted a conveyor chain assembly 12.

The conveyor assembly is comprised of a series of pivotally interconnected links 13 (FIG. 8), adjacent links 13 being secured together by straps 14, the distal ends of which straps are pivotally secured to inwardly facing brackets 15, 16 of adjacent links 13. The links 13 are arrayed in the form of an endless loop movable in'a horizontal plane.

Motive power for the conveyor 12 is provided by a drive motor 17 operating through speed reduction unit 18, drive shaft 19 carrying at its uppermost end a sprocket wheel (not shown) in driving connection with the conveyor chain 12.

Shaft 20, at the opposite end of the frame, carries an idler sprocket (not shown) engaging the conveyor chain 12 and maintaining the same in a tautened condition.

Links or plates 13 ride within upper and lower trackways 21, 22 defined by brackets 23, 24, respectively, the brackets having downwardly and upwardly extending lips 25, 26, respectively. The plates 13 are prevented from moving in an outward direction by the lips 25, 26, inward boundary for the plates being provided at the upper end by the outwardly facing margin 27 of guide plate 28.

In similar fashion, the lowermost edge 29 of the plates 13 may ride on a shim or flange 30 clamped to the platform 11 by bolts 31. Preferably spacer webs 32 are similarly supported on the platform 11 by the bolts 31, the outer side edge of the spacer webs 32 defining with the lip 26 the guideway 24 for the lower edge of the plates 13.

It will be appreciated that the guideways 21 and-22 extend only along the parallel side runs of the conveyor 12, the end portions of the conveyor which are required to traverse semi-circular arcs being clear'of guideways so as to permit the pivotal movement of the plates 13 as the plates pass from one parallel flight to the other.

It willbe evident that the specific chain and guide construction has been described for illustrative purposes only, and substantial variations in structural detail may be made without departing from the spirit of the instant invention.

As will be more clearly understood from the ensuing description, the plates 13 support ferrule carrier housings 33 which, with the movement of the conveyor 12, are progressively advanced from .a load zone 34 through an alignment zone 35, along heating zone 36 extending essentially the entire length of one of the conveyor flights, and lastly to an eject zone 37 whereat the formed bristle-ferrule sub-components are discharged from the apparatus.

Heat for the apparatus is provided by a series of heating lamp assemblies 38, seven such assemblies being shown in the illustrated embodiment. The assemblies 38 are mounted so as to be shiftable in a horizontal plane, suchthat the heating components thereof, preferably infra red quartz lamps 39, may be centered above the ferrules as the same are advanced by the conveyor 12.

The heat lamp assemblies 38 include a housing 40 within which the lamps 39 are mounted, the housing being made fast to an extensible bracket 41 movably mounted over the guide plate 28. The housing and bracket may be bodily shifted in the direction D (see FIG. 7) by operation of the handle component 42 of toggle assembly 43.

The toggle includes a first branch 44 fixed to the guide plate 28, and a drive rod 45 connected to arm 46 of bracket 41. Due to the eccentric mounting of the shaft 47 of the adjustment toggle assembly 43, movement of the handle 42 in one direction or another will bodily shift the bracket 41 and the heater lampassembly fixed thereto inwardly and outwardly in the direction D. The inward and outward adjustability of the lamp assemblies permits the heater lamp 39 to be centrally located directly above the ferrules F carried by the conveyor 12. 7 It will be appreciated that in various brush sizes, eg 2 inches, 4 inches, 6 inches widths, the transverse or thickness dimension of the ferrules will typically vary, becoming proportionately greater with the width of the brush, the lateral adjustability provided by the toggle assembly 43 permitting the requisite centering of the heat lamp 39 for virtually any size of ferrule to be processed.

As with the conveyor chain assembly, it will be appreciated that the means for adjusting the position of the heat lamp may be modified, any suitable mechanism enabling a centering of the heat source over the ferrule being acceptable.

. In the course of the heating step, substantial quantities of fumes may be generated. In order to carry away the vapors and fumes, there is provided a central manifold 50 connected to an exhaust pump 51 which is, in turn, vented to the exterior of the building within which the apparatus is housed. A plurality of tubular conduits 52 connect each heat lamp subassembly 38 to the exhaust manifold 50.

Selected ones of the plates 13 are provided with support brackets 53 which carry vertical mounting plates 54 for the ferrule carrier housings 33. The housings 33 are releasibly secured to the plates 54 by a bayonet type mounting mechanism.

The bayonet mounting mechanism includes vertically directed slots 55 (see FIGS. 9 and 10) formed in the plates 54, the slots including an enlarged entrance component 56 at the upper portion and a reduced locking component 57 at the lowermost terminal end of the slots 55. Each plate 54 includes two or more slot assemblies of the type described.

The ferrule carrier housings 33 include inwardly directed studs 58 extending from wall 58', the studs being spaced apart to correspond with the spacing of the slots 55. The studs include shank portions 59 and heads 60.

As will be evident from the above description, the ferrule housings 33 are secured to the plates 54 by aligning the head portions 60 of the studs with the enlarged entrance portions 56 of the slots, passing the heads inwardly through the enlarged portions 56 and thereafter moving the housings 33 in a downward direction, whereupon the housings are locked to the plate against movement in an outward direction.

As will be more fully set forth hereafter, removable housings are provided since each size of ferrule-bristle composite is required to be contained within a receptacle proportioned to accommodate the specificcomposite.

Referring now to FIGS. 4 to 9, the ferrule carrier housings 33 include essentially a three-sided perimeter or rim having a leading side wall 61, a trailing side wall 62 and a bottom wall 63. A plurality'of vertically directed separator bars 64 extend upwardly from the bottom wall 63, the bars 64 dividing the space between the lead wall 61 and the trailing wall 62 into individual compartments. While the compartments have been illustrated without an outer shield paralleling wall 58 and covering the exposed sides of the bristles, it is within the contemplation of the present invention to provide such a shield member whereby the side faces of the bristles are protected from excessive heat.

It will be further appreciated that where larger or smaller ferrules are to be treated, the number of subdivisions should be modified as required.

Fixedly secured to the mounting plates 54 supporting the receptacles 33 are a series of permanent magnet members 65. The permanent magnets, which are preferably of the ceramic type, are clamped to the plate 54 by machine screws 66 passing through the magnets and threaded into the plate. The exposed vertical face portions 67 of the magnets are in a plane vertically aligned with the vertically directed face portions 68 of the rear wall portion 58' of the receptacles 33, such that the face 68 of the receptacles forms a downward continuation of the surface 67 of the magnets.

As previously noted, the process of integrating the bristles by heating and fusing the molten bristle material to the interior surface of the ferrule is extremely critical as respects the amount of heat to be applied. Specifically, as set forth in the above referred to copending application, a thin layer of adhesive may be secured to the interior surface of the ferrule adjacent the area where the fused bristle mass is to flow. In the event of overheating, the thin layer of adhesive will be severely degraded, compromising the attachment of the molten bristle material to the ferrule. Similarly, overheating may result in a burning or carbonization. Obviously, underheating to an extent which prevents satisfactory melt and adhesion of the bristles is also undesirable.

It will be manifest thatthe quantum of heat applied to each ferrule in the course of traversing the heating lamp assemblies 38 is a function of the speed of adsame of the conveyor and the distance of the ferrule, and particularly of the bristle ends within the ferrule,

' from the lamps. Controlling the speed of advance is a simple matter, for which purpose the variable speed drive assembly, as previously noted,'is-incorporated in the conveyor drive mechanism.

In order to assure a precise heightwise orientationof the ferrules relative to the heat lamps without-themecessity for careful and individual insertion of each ferrule into a compartment within a receptacle 33, there is provided in accordance with the present invention a height adjustment assembly next to be described.

The height adjustment assembly, best depicted in FIGS. 4 and 5, includes a locator plate 70 fixed, as by a machine screw or screws 71, to the longitudinally extending bracket 23 previously described. The locator plate 70 includes an upturned locator cam surface 72 extending laterally beyond the bracket 23.

As best seen in FIGS. 4 and 5, the undersurfac e 73 of the plate 70, including as a portion of said undersurface the cam 72, is disposed in the path of ferrule members as the same move in the direction of the arrow 74 (see FIGS. 4 and 5).

The operation of the device will be apparent from the preceding description. An operator standing in the load zone 34 (see FIGS. 1 and 4) will place individual ferrules, suitably stuffed with bristles temporarily mounted therein, as by a retaining wedge, into the individual receptacles defined between the partitions 64 in the carriers 33. The heightwise location of the ferrules relative to the carriers need not be carefully established, whereby the leading operation may be rapidly carried out, the sole responsibility of the operator being to assure that the upper edge portions 75 of the ferrules are disposed at a level sufficiently high to enable the same to be engaged against the cam surface 72 of the locator plate 70. The magnets 65 will maintain the ferrules, which are formed of a magnetically responsive material such as steel, in the position in which they are placed by the operator.

It will be appreciated that the device is continuously moving, and as the ferrules are carried from the loading zone 34 beyond the locator plate'70, the cam portions 72 will coact with the upper surfaces 75 of the ferrules, to urge the ferrules downwardly to a predetermined heightwise position defined by the lowermost portion of the undersurface 73 of the plate 70.

Movement of the ferrules relative to the'carriers 33 is permitted by the fact that the ferrules are slidingly supported on the surface of the magnets. Tilting movement of the ferrules from the vertical position illustrated is positively prevented by the interaction of the leading and trailing edges of the ferrules with the vertically extending partitions 64, whereby the camming action of the plate 70 on the ferrules will effect an up and down movement of the ferrules but not a-tilting or rotary movement.

As will be apparent from an inspection of FIG. 1, the ferrules, haphazardly heightwiselyaligned within the receptacles, are shifted from the loading zone,through the alignment zone defined by the cam plate 70, and thence to a heating zone 36 beneath the lamps 38. As previously noted, the lamps may be shifted in a horizontal plane, depending upon the thickness of the ferrules, so as to be essentially centered above the mass of bristleswithin the ferrules.

As fully set forth in the copending application, the heat lamps cause a melting of the uppermost bristle components, uniting the same at a molten skin line formed at the top surface, at the same time-molten material of the bristle mass preferably flowing into contact witha heat activated adhesive layer on the interior. surface of the ferrule, resulting in the formation of a tight,

solvent-resistant interconnection between the noted parts. I

The completed ferrules continue to be carried beyond the heating zone 36 to an eject zone 37, whereat there is located a cam member 76 having a lateral, outwardly inclined face 77. The inclined face 77 is positioned to engage behind the ferrule portions at a level above the wall portions 61, 62, and dividers 64 of the receptacles 33, the cam functioning, as the ferrules are shifted adjacent the cam station, to deflect the ferrules laterally outwardly into an appropriately positioned receptacle (not shown).

From the foregoing it will be understood that there is provided apparatus for automatically fabricating, through a heat processing step, composite ferrulebristle units utilizing thermoplastic bristles, wherein the heating step is employed to unite the bristle ends into a single, integral mass.

The critical heightwise alignment of the ferrules relative to the heating elements is automatically and precisely accomplished without the requirement for carefully positioning the individual ferrule elements, and without the necessity of providing complex adjustable gripper or like elements, whereby production speeds are greatly accelerated as compared to a procedure in which heightwise orientation is required to be effected by the operator.

As a further means for expediting the speed of loading, use may be made of the ready deflectibility of the bristle ends, i.e., the floor of the individual receptacles for the ferrules may be positioned at a height such that the operator need merely insert the ferrules so that the bristle ends are supported on the floor. Obviously the variables in the length of bristles and their resilience would preclude such step from providing a heightwise orientation of requisite precision. However, utilization of the bristle lengths would be sufficient to orient the ferrules at a proper height to assure their engagement with the locator plate 70, downward movement of the ferrules by the plate being accommodated by a degree of deflection of the bristles.

It will be appreciated from the preceding description that variations in the specific apparatus employed may be made without departing from the spirit ofthe invention. Accordingly, the invention is to be broadly construed within the scope of the appended claims.

Having thus described the invention and illustrated its use, what is claimed as new and is desired to be secured by Letters Patent is:

1. Apparatus for fabricating brushes having thermoplastic bristles, comprising conveyor means, drive means for advancing said conveyor means along a predetermined path progressively to advance increments of said conveyor means through a loading zone and adjacent a heating zone, heater means in said zone spaced a predetermined distance from said conveyor means, a plurality of magnet means carried at spacedintervals on said conveyor means for magnetically supporting ferrous brush ferrules on said conveyor, and cam means interposed between said loading and heating zones positioned to engage the upper edge portions of said supported ferrules, said cam means being angularly oriented with respect to the path of movement of said conveyor and with respect to said parallel direction for shifting said supported ferrules to a preselected position relative to said magnet means, thus to space said ferrules a selected distance from said heater means.

2. Apparatus in accordance with claim 1 and including guide means on said conveyor surrounding said magnetic means positioned to engage the lead and trailing edges of said supported ferrules carried by said magnet means, for cooperating with said side edges to prevent tilting movements of said ferrules while permitting relative movements between said ferrules and magnet means in a direction parallel to said side edges.

3. Apparatus in accordance with claim 2 and including ejector cam means downstream from said heating zone positioned to enter between said ferrules and magnet means and laterally deflect said ferrules to release the latter from said magnet means.

4.Apparatus in accordance with claim 1 and including means for adjusting the position of said heater means in a plane normal to the plane of movement of said ferrules traversing said heating zone. 

1. Apparatus for fabricating brushes having thermoplastic bristles, comprising conveyor means, drive means for advancing said conveyor means along a predetermined path progressively to advance increments of said conveyor means through a loading zone and adjacent a heating zone, heater means in said zone spaced a predetermined distance from said conveyor means, a plurality of magnet means carried at spaced intervals on said conveyor means for magnetically supporting ferrous brush ferrules on said conveyor, and cam means interposed between said loading and heating zones positioned to engage the upper edge portions of said supported ferrules, said cam means being angularly oriented with respect to the path of movement of said conveyor and with respect to said parallel direction for shifting said supported ferrules to a preselected position relative to said magnet means, thus to space said ferrules a selected distance from said heater means.
 2. Apparatus in accordance with claim 1 and including guide means on said conveyor surrounding said magnetic means positioned to engage the lead and trailing edges of said supported ferrules carried by said magnet means, for cooperating with said side edges to prevent tilting movements of said ferrules while permitting relative movements between said ferrules and magnet means in a direction parallel to said side edges.
 3. Apparatus in accordance with claim 2 and including ejector cam means downstream from said heating zone positioned to enter between said ferrules and magnet means and laterally deflect said ferrules to release the latter from said magnet means.
 4. Apparatus in accordance with claim 1 and including means for adjusting the position of said heater means in a plane normal to the plane of movement of said ferrules traversing said heating zone. 